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Abstract:

In accordance with one embodiment of the present disclosure, a carrier
for a container for processing the container in a rotary processing
system generally includes a carrier body defining at least one
compartment for receiving at least one container, wherein the carrier is
capable of rolling, and a retention system for maintaining the at least
one container in the at least one compartment and restricting movement of
the at least one container within the at least one compartment.

Claims:

1. A carrier for a container for processing the container in a rotary
processing system, the carrier comprising: (a) a carrier body defining at
least one compartment for receiving at least one container, wherein the
carrier is capable of rolling; and (b) a retention system for maintaining
the at least one container in the at least one compartment and
restricting movement of the at least one container within the at least
one compartment.

2. The carrier of claim 1, wherein the carrier is substantially
cylindrical.

3. The carrier of claim 1, wherein the carrier has substantially circular
ends.

4. The carrier of claim 1, wherein the retention system includes a
retention device and biasing member for biasing the retention device
between a retaining position and a loading position.

5. The carrier of claim 1, wherein the retention system does not separate
from the carrier body.

6. The carrier of claim 4, wherein the biasing member is normally biased
in the retaining position.

7. The carrier of claim 4, wherein the biasing member is normally biased
in the loading position.

8. The carrier of claim 4, wherein the biasing member is a leaf spring.

9. The carrier of claim 4, wherein the biasing member is a spring.

10. The carrier of claim 1, wherein the retention system further includes
a hinge about which the retention device rotates between retaining and
loading positions.

11. The carrier of claim 1, wherein the retention system includes a
position limiting assembly.

12. The carrier of claim 11, wherein the position limiting assembly may
be fixed in at least a first position.

13. The carrier of claim 11, wherein the position limiting assembly may
be fixed in at least first and second positions.

14. The carrier of claim 11, wherein the position limiting assembly may
be fixed in at least first, second, and third positions.

15. The carrier of claim 1, wherein the at least one container is a
flexible container having movable contents.

16. The carrier of claim 1, wherein the retention system provides
resistance against the at least one container to distribute the movable
contents substantially evenly throughout the at least container.

17. The carrier of claim 1, wherein the at least one container is a
fragile container.

18. The carrier of claim 1, wherein the at least one container is an
irregularly shaped container.

19. The carrier of claim 1, wherein the compartments are sleeves.

20. The carrier of claim 1, wherein the retention system includes first
and second compartments hingedly coupled to one another between open and
closed positions and defining a cylinder in the closed position.

21. The carrier of claim 1, wherein the carrier body has a body portion
and first and second ends, and wherein the retention system only
interfaces with the first and second ends of the at least one container.

22. A carrier for a container for processing the container in a rotary
processing system, the carrier comprising: (a) a carrier body defining at
least one compartment for receiving at least one container; and (b) a
removable outer shell for the carrier body.

23. The carrier of claim 22, wherein the compartments are configured for
receiving one or more containers selected from the group consisting of
bottles, tubs, pouches, and laminate containers.

24. A method of loading a carrier with a container, the method
comprising: (a) obtaining a carrier defining at least one compartment for
receiving at least one container and a retention system for maintaining
the at least one container in the at least one compartment; (b) loading
the at least one container in the at least one compartment; and (c)
activating the retention system to restrict the movement of the at least
one container within the at least one compartment.

25. The method of claim 24, further comprising deactivating a retention
system prior to loading the at least one container in the at least one
compartment.

26. A method of loading a carrier with a container, the method
comprising: (a) obtaining a carrier defining first and second
compartments hingedly coupled to one another between open and closed
positions and defining a cylinder when in the closed position; (b)
placing the first and second compartments in the open positions and
receiving at least one container in either of the first and second
compartments; (c) restricting the movement of the at least one container
within either of the first and second compartments; and (d) hingedly
coupling the first and second compartments in the closed position to
define a carrier.

27. A method of processing a container in a rotary processing system, the
method comprising: (a) placing at least one container in a carrier; and
(b) receiving the at least one carrier in the rotary system.

28. The method of claim 27, wherein the rotary system includes an
agitating reel.

29. The method of claim 27, wherein the rotary system includes a
non-agitating reel.

30. The method of claim 27, wherein the rotary system is a rotary
sterilizer.

31. A system for unloading a container from a carrier having at least one
compartment for receiving at least one container and a retention system
for maintaining the at least one container in the at least one
compartment, the system comprising: (a) a conveyor assembly for conveying
the carrier in a controlled path; and (b) an unloading assembly for
opening the at least one compartment.

32. The system of claim 31, wherein the conveyor assembly supports the
carrier by supporting at least one of the first and second ends of the
carrier.

33. The system of claim 31, wherein the conveyor assembly does not rotate
the carrier.

34. The system of claim 31, further comprising a container receiving
assembly for receiving the at least one container from the opened at
least one compartment.

35. The system of claim 31, wherein the conveyor system includes first
and second laterally spaced-apart conveyors.

36. The system of claim 31, wherein the compartment has an openable end,
and wherein the carrier is received with the openable end directed
substantially downward.

37. The system of claim 31, wherein the unloading assembly deactivates
the retention system.

38. The system of claim 31, wherein gravity assists to release the at
least one container from the at least one compartment.

39. The system of claim 31, wherein the unloading assembly is an
intermittent unloading assembly.

40. The system of claim 31, wherein the unloading assembly is a
continuous unloading assembly.

41. The system of claim 31, further comprising a receiving assembly for
receiving the at least one container.

42. A method for unloading a container from a carrier, the method
comprising: (a) receiving on a conveyor assembly, a carrier having at
least one compartment for receiving at least one container and a
retention system for maintaining the at least one container in the at
least one compartment, wherein the conveyor assembly is configured for
conveying the carrier in a controlled path; and (b) opening the at least
one compartment.

43. The method of claim 42, wherein the conveyor assembly supports the
carrier by supporting at least one of the first and second ends of the
carrier.

44. The method of claim 42, wherein the conveyor assembly does not rotate
the carrier.

45. The method of claim 42, further comprising receiving the at least one
container from the opened at least one compartment.

Description:

CROSS-REFERENCES TO RELATED APPLICATIONS

[0001] This application claims the benefit of U.S. Provisional Application
Nos. 61/566,524, filed Dec. 2, 2011, and 61/510,419 filed Jul. 21, 2011,
the disclosures of which are hereby expressly incorporated by reference
in their entirety herein.

BACKGROUND

[0002] In food processing, various types of continuous sterilization
apparatuses have been used for sterilizing cans. While cans are still
very popular for containing and processing foods, pouches and other types
of containers are also becoming more widely used for food processing. For
some food products, pouches are preferred because they are easier to open
and easier to dispose of than cans. However, continuous processes, such
as continuous rotary sterilization processes are designed for use with
cylindrical cans and not for pouches.

[0003] Carriers designed for use with continuous sterilization apparatuses
that are capable of holding irregularly shaped and/or fragile containers,
such as bottles, flat pouches, and other containers have been developed
in the past. See, for example, U.S. Pat. Nos. 3,314,560, 4,385,035, and
5,245,916. Although effective, these carriers require assembly of
multiple parts, adding complexity to the overall process. Because these
carriers have not been optimized for ease of use, there exists a need for
optimized carriers for processing irregularly shaped and/or fragile
containers, including, but not limited to, pouches, thin-walled cans,
bottles, tubs, and other containers.

SUMMARY

[0004] This summary is provided to introduce a selection of concepts in a
simplified form that are further described below in the Detailed
Description. This summary is not intended to identify key features of the
claimed subject matter, nor is it intended to be used as an aid in
determining the scope of the claimed subject matter.

[0005] In accordance with one embodiment of the present disclosure, a
carrier for a container for processing the container in a rotary
processing system is provided. The carrier generally includes a carrier
body defining at least one compartment for receiving at least one
container, wherein the carrier is capable of rolling, and a retention
system for maintaining the at least one container in the at least one
compartment and restricting movement of the at least one container within
the at least one compartment.

[0006] In accordance with another embodiment of the present disclosure, a
carrier for a container for processing the container in a rotary
processing system is provided. The carrier generally includes a carrier
body defining at least one compartment for receiving at least one
container, and a removable outer shell for the carrier body.

[0007] In accordance with another embodiment of the present disclosure, a
method of loading a carrier with a container is provided. The method
generally includes obtaining a carrier defining at least one compartment
for receiving at least one container and a retention system for
maintaining the at least one container in the at least one compartment.
The method further includes loading the at least one container in the at
least one compartment, and activating the retention system to restrict
the movement of the at least one container within the at least one
compartment.

[0008] In accordance with another embodiment of the present disclosure, a
method of loading a carrier with a container is provided. The method
generally includes obtaining a carrier defining first and second
compartments hingedly coupled to one another between open and closed
positions and defining a cylinder when in the closed position. The method
further includes placing the first and second compartments in the open
positions and receiving at least one container in either of the first and
second compartments, restricting the movement of the at least one
container within either of the first and second compartments, and
hingedly coupling the first and second compartments in the closed
position to define a carrier.

[0009] In accordance with another embodiment of the present disclosure, a
method of processing a container in a rotary processing system is
provided. The method generally includes placing at least one container in
a carrier, and receiving the at least one carrier in the rotary system.

[0010] In accordance with another embodiment of the present disclosure, a
system for unloading a container from a carrier having at least one
compartment for receiving at least one container and a retention system
for maintaining the at least one container in the at least one
compartment is provided. The system generally includes a conveyor
assembly for conveying the carrier in a controlled path, and an unloading
assembly for opening the at least one compartment.

[0011] In accordance with another embodiment of the present disclosure, a
method for unloading a container from a carrier is provided. The method
generally includes receiving on a conveyor assembly, a carrier having at
least one compartment for receiving at least one container and a
retention system for maintaining the at least one container in the at
least one compartment, wherein the conveyor assembly is configured for
conveying the carrier in a controlled path, and opening the at least one
compartment.

DESCRIPTION OF THE DRAWINGS

[0012] The foregoing aspects and many of the attendant advantages of this
disclosure will become more readily appreciated by reference to the
following detailed description, when taken in conjunction with the
accompanying drawings, wherein:

[0013] FIG. 1 is a front view of a rotary sterilizer, which is in the
process of rotating two pouch carriers that have been designed in
accordance with one embodiment of the present disclosure;

[0014] FIG. 2 is an isometric view of the pouch carrier shown in FIG. 1,
showing pouches being inserted into the pouch carrier;

[0015] FIG. 3 is an isometric view of a pouch carrier in accordance with
another embodiment of the present disclosure;

[0016] FIGS. 4 and 5 are side cross-sectional views of the pouch carrier
of FIG. 3, showing pouches in the pouch sleeves;

[0017] FIGS. 6A-15B are various views of various examples of sleeve
retention mechanisms for pouch carriers in accordance with embodiments of
the present disclosure;

[0018] FIGS. 16A-16C are top views of various examples of sleeve shapes
and configurations for pouch carriers in accordance with embodiments of
the present disclosure;

[0019] FIG. 17 is a top view of trapezoidal sleeve shape shown in FIG.
16A, combined with a sleeve retention mechanism, similar to that shown in
FIGS. 14A and 14B, in accordance with one embodiment of the present
disclosure;

[0020] FIGS. 18-20 are directed to various designs for rotary sterilizers
in accordance with embodiments of the present disclosure;

[0021] FIGS. 21-23 are various views of systems for processing pouch
carriers in accordance with embodiments of the present disclosure;

[0022] FIG. 24 is an isometric view of a bottle carrier in accordance with
another embodiment of the present disclosure;

[0023] FIG. 25 is an isometric view of a tub carrier in accordance with
another embodiment of the present disclosure;

[0024] FIG. 26 is an isometric view of a laminate container carrier in
accordance with another embodiment of the present disclosure;

[0025] FIG. 27 is an exploded view of the carriers shown in FIGS. 24 and
25, showing interchangeability between carrier sleeve portions and outer
shell portions;

[0026] FIGS. 28-29B are isometric view of carriers in accordance with
other embodiments of the present disclosure; and

[0027] FIGS. 30-38 are views of various embodiments of carriers designed
for holding fragile containers, such as thin-walled cans and plastic
bottles.

DETAILED DESCRIPTION

[0028] The detailed description set forth below in connection with the
appended drawings, where like numerals reference like elements, is
intended as a description of various embodiments of the disclosed subject
matter and is not intended to represent the only embodiments. Each
embodiment described in this disclosure is provided merely as an example
or illustration and should not be construed as preferred or advantageous
over other embodiments. The illustrative examples provided herein are not
intended to be exhaustive or to limit the disclosure to the precise forms
disclosed. Similarly, any steps described herein may be interchangeable
with other steps, or combinations of steps, in order to achieve the same
or substantially similar result.

[0029] In the following description, numerous specific details are set
forth in order to provide a thorough understanding of exemplary
embodiments of the present disclosure. It will be apparent to one skilled
in the art, however, that many embodiments of the present disclosure may
be practiced without some or all of the specific details. In some
instances, well-known process steps have not been described in detail in
order not to unnecessarily obscure various aspects of the present
disclosure. Further, it will be appreciated that embodiments of the
present disclosure may employ any combination of features described
herein.

[0030] Embodiments of the present disclosure are directed to carriers for
irregularly shaped and/or fragile containers or other objects, such as
pouches, bottles, thin-walled cans, tubs, fiberboard containers,
fiberboard and plastic laminate containers (such as TETRA RECART®
containers), and other objects. The various carriers and methods
described herein are particularly useful in cooking and sterilization
processes using rotary systems, such as rotary sterilizers. However, it
should be appreciated that the carriers described herein may also be
useful in other non-food-related rotary processes.

[0031] Referring to FIGS. 1 and 2, an exemplary pouch carrier 20 in
accordance with embodiments of the present disclosure is shown. In the
illustrated embodiment of FIG. 1, the pouch carrier 20 is designed to
behave like a cylindrical can when used in a rotary sterilizer R (see
also FIGS. 18-20 for other exemplary configurations and designs for
rotary systems, such as rotary sterilizers). As can be seen in FIG. 2,
the pouch carrier 20 has first and second circular ends 22 and 24 and a
cylindrical outer shell portion 26. The first end 22 includes a plurality
of sleeve openings 28 for receiving pouches P (see FIG. 3).

[0032] The pouch carrier 20 is preferably a one-piece assembly for easily
receiving a pouch P without requiring assembly or disassembly. For
example, the pouch carrier 20 does not have a clam shell structure, a
tray assembly, or a capsule assembly, for enclosing a container on all
sides after the container has been received by the carrier, as described
in respective U.S. Pat. Nos. 5,245,916, 4,385,035, and 3,314,560 for
previously developed technologies, the disclosures of which are hereby
expressly incorporated by reference herein.

[0033] Referring now to FIGS. 3-5, an alternate embodiment of a pouch
carrier 100 is shown. This embodiment is substantially similar to the
pouch carrier 20 shown in FIGS. 2 and 3, except for differences regarding
the outer shell. In that regard, in the illustrated embodiment of FIGS.
3-5, the carrier 100 has no outer shell, exposing the body portion 112 of
the carrier, which defines the structure of the pouch sleeves 110. Like
the pouch carrier 20 shown in FIG. 2, the pouch carrier 100 shown in
FIGS. 3-5 is also suitably configured as a one-piece assembly. Although
the pouch carrier 100 of FIGS. 3-5 does not include an outer shell,
rolling action of the carrier 100 is enabled by the first and second
circular ends 102 and 104 (which may include an optional outer lip 114
extending from the outer perimeter of the first and second circular ends
102 and 104, see FIGS. 4 and 5).

[0034] As seen in the illustrated embodiments, the carriers may include
perforated portions. In that regard, the walls of the outer shell portion
26 in FIG. 2 and body portion 112 in FIG. 3 are shown as being
perforated. Such perforations allow for efficient and consistent heat
transfer to or from the pouch P during processing, for example, steam may
travel through the walls of the carrier 100 to reach the pouch P. In
accordance with embodiments of the present disclosure, suitable
perforations may be about 0.20 inches in diameter. However, other sizes
are also within the scope of the present disclosure. It should further be
appreciated that, in accordance with embodiments of the present
disclosure, the body portion 112 need not be made from a perforated
material.

[0035] As shown in the illustrated embodiments of FIGS. 1-5, the pouch
carriers 20 and 100 include two pouch sleeves. However, it should be
appreciated that the pouch carriers 20 and 100 may include any number of
pouch sleeves to accommodate various shapes and sizes of pouches.
Further, although shown in the illustrated embodiments as having
rectangular shaped cross-sections, the pouch sleeves may have other
suitable cross-sectional shapes. For example, suitable cross-sectional
shapes may include, but are not limited to, trapezoidal, having tapered
ends, and curved, as described in greater detail below with reference to
FIGS. 16A-16C.

[0036] Returning to FIG. 2, the pouches P to be carried by the pouch
carriers are generally made of film laminated from layers of plastic
and/or foil. The pouches P may be designed for containing various food
products, including liquid products or more solid products, such as soups
or stews. The pouches P generally each have a thickness when filled.
Seams S around the outer peripheral edge of the pouch P contain the
products. As seen in the illustrated embodiment, the pouches may be
rectangular shaped or another suitable shape as deemed to be desirable
for specific food products, processing parameters, or handling
requirements.

[0037] Referring to the cross-sectional view of the body portion 112 in
FIGS. 4 and 5, the sleeve openings 108 and the sleeves 110 are sized to
allow for gentle and quick loading of the pouches P without damage to the
pouches P. In that regard, the sleeve openings 108 and the sleeves 110
themselves are suitably sized and shaped to receive pouches P. The
sleeves 110 may be designed to adjust the contents of the pouches P to
provide for substantially even pouch thickness along the length of the
pouch. In that regard, the dimensions of the sleeves 110 may provide
enough resistance and gentle "squeeze" on the pouch contents to
effectively retain the pouches P within the sleeves 110, even during
movement of the pouch container 100 (see, e.g., movement in the rotary
sterilizer shown in FIG. 1). Referring to FIG. 4, the pouch carrier 100
is shown holding two larger sized pouches P. Referring to FIG. 5, the
pouch carrier 100 is shown holding four smaller sized pouches P in a
stack of two in each sleeve 110.

[0038] After pouches P have been received in the sleeves 110, the sleeves
110 may include a retention system to further retain the pouches P within
the sleeves 110 and/or to more evenly distribute the pouch contents
within the pouch P for more even pouch thickness distribution within the
sleeve. Suitable retention systems are used to minimize pouch movement
when the pouch carrier 100 moves to minimize scuffing or wrinkling of the
pouches P. Minimizing pouch scuffing and wrinkling not only preserves
pouch aesthetics, but also pouch integrity. Moreover, retention systems
that provide more even pouch thickness distribution within the sleeve 110
will provide for more consistent heat transfer to the contents in the
pouches P. As a one-piece assembly, suitable retention systems are
designed so that they do not separate from the body portion 112 of the
carrier 100.

[0039] With reference to FIGS. 6A-17, various embodiments of pouch loading
and retention devices are shown. For example, referring to FIG. 6A, the
outer sleeve wall 220 may be movable from its normally biased closed
position (see right side sleeve for normal biased position) to open the
sleeve 210 beyond its normal size to allow a user to easily slide a pouch
P into the sleeve 210 (see left side sleeve for opened position). When
the outer sleeve wall 220 is released, it biases back toward its normal
position to gently "squeeze" the pouch P.

[0040] In the illustrated embodiment of FIG. 6A, the outer pouch wall 220
is coupled by a hinge 222 to the second end 204 of the body portion 212.
A biasing member 224 (such as a compression coil spring or other type of
biasing member) adjacent the first end 202 of the body portion 212 is
normally biased in the closed position (such as the parallel wall
position shown in FIG. 6A). When loading and unloading, a pulling device
D, such as a stationary cam or a pull actuator, can be used to engage
with a handle 226 to pull the outer wall 220 to the opened position.
After the pouch P has been loaded, the bulge of the pouch P may resist
the outer wall 220 as it extends to the closed position, thereby holding
the pouch in a gently "squeezed" position.

[0041] Of note, the opening 208 in the first end 202 of the body portion
212 is larger than the normally biased closed position to allow for
loading of the pouch when the outer pouch wall 220 is in the opened
position. Referring to FIG. 6B, the opening 208 in the first end 202 of
the body portion 212 may include an optional lip 214 extending inwardly
from the outer wall 220 to further assist with retention of the pouch P
in the sleeve 210.

[0042] Referring to FIGS. 7A and 7B, respective side isometric and top
views of an exemplary hinged retention carrier 300 (similar to the
embodiments in FIGS. 6A and 6B) are shown. The sleeves 310 (see FIG. 7B)
includes first and second upright sleeve walls 330 and 332. The first
sleeve wall 330 is rotatable relative to the second end 304 of the
carrier 300 about a hinge (not shown, but positioned along the bottom of
wall 330). Biasing members 324 (shown as coil springs) are attached to
stationary brackets 334. The biasing members 324 bias the first sleeve
wall 330 to a closed position (see FIG. 7B). Handle 336 (see FIG. 7A) can
be grasped or otherwise used to pull the rotatable first sleeve wall 330
to an open position to insert or release the pouch P (shown in the left
side FIG. 7B to be contained within the sleeve 310). In the illustrated
embodiment, handle 336 is pulled through a hole in a stationary wall 340.

[0043] The carrier 300 may further include an adjustable stop (not shown)
to limit the travel distance of the first sleeve wall 330 to the closed
position. As a non-limiting example, the adjustable stop may be a bolt or
threaded stud attached to the first sleeve wall 330 and passing through a
hole 338 in the stationary wall 340. The adjustable stop may, for
example, includes adjustable nuts which rest against the stationary wall
340 or at least one of the stationary brackets 334 to limit the travel
distance of the second sleeve relative to the stationary wall 340 or at
least one of the stationary brackets 334.

[0044] Referring now to FIG. 8, another embodiment of a hinged retention
carrier 400 is shown (similar to the embodiments of FIGS. 6A-7B). The
carrier 400 includes a position limiter assembly 440 to limit the travel
distance of the second sleeve wall 420 coupled to hinge 422. The position
limiter assembly 440 includes a position limiting device 442 that extends
outwardly from the outer sleeve wall 420, and a stationary surface 412 to
which the position limiting device 442 may releasably couple.

[0045] In the illustrated embodiment of FIG. 8, the position limiting
device 442 includes a first contact surface 446 and a second contact
surface 448, which are capable of coupling with the stationary surface in
two different sleeve positions, for example, a processing position and a
loading/unloading position (e.g., compare positioning of right side
sleeve 410 with left side sleeve 410 in FIG. 8). In the illustrated
embodiment, the stationary surface 412 includes a substantially vertical
wall 450, for example, projecting downward from the first end 402 of the
carrier 400. The stationary surface 412 further includes a slot or hole
452 through which the position limiting device 442 is received.

[0046] It should be appreciated that the position limiting device 442 may
be made from a flat spring material, such that it is capable of bending
or flexing when in either of the first and second sleeve positions (e.g.,
compare positioning of right side sleeve 410 with left side sleeve 410 in
FIG. 8). In that regard, looking at the right side sleeve 410, the first
contact surface 446 of the position limiting device 442 passes through
slot or hole 452 and engages with an upper outer surface of the
substantially vertical wall 450 of the stationary surface 412. This
engagement maintains the sleeve 410 in a position for pouch retention to
a width Wt and prevents the outer sleeve wall 420 from collapsing
inwardly.

[0047] Now looking to the left side sleeve 410, the second contact surface
448 of the position limiting device 442 engages with a lower outer
surface of the substantially vertical wall 450 of the stationary surface
412. The transition from the first position (see right side sleeve 410)
to the second position (see left side sleeve 410) is achieved by pulling
the outer sleeve wall 420 outwardly (for example, using pulling device D
to hook downwardly extending flange 426) from the first position to the
second position. As the position limiting device 442 moves outwardly
through hole 452, the second contact surface 448 engages with the lower
outer surface of the substantially vertical wall 450 of the stationary
surface 412. In the second position, the sleeve 410 will remain open for
loading or unloading.

[0048] The second contact surface 448 in the illustrated embodiment, is
shown as a catch or tab with a cam ramp surface that is configured to
engage with a lower edge of slot 452. The cam ramp surface allows for the
transition from the first position to the second position while
minimizing the risk of the position limiting device 442 catching en
route. To transition from the second position back to the first position,
the position limiting device 442 is lifted upwards to disengage the
second contact surface 448 from the lower outer surface of the
substantially vertical wall 450 of the stationary surface 412.

[0049] In the illustrated embodiment, the second sleeve wall 420 is
normally biased in the closed position, with the wall being biased to a
tapered position, having a smaller nominal sleeve width Wt at the top of
the sleeve than at the bottom of the sleeve Wb. The inventors have found
that a sleeve having a tapering width (as shown narrower at the top Wt
and wider at the bottom Wb) helps to maintain the pouch (not shown) in
the sleeve. It should further be appreciated that the sleeve closed
position can be designed and dimensioned (depending on the size and shape
of the specific pouch to be received) to substantially evenly distribute
the contents in the pouch by bearing against a substantial surface area
of the pouch. Such substantially even distribution can provide for more
even heat transfer to the contents in the pouch for predictable and
repeatable thermal processing.

[0050] Referring now to FIG. 9, another embodiment of a pouch retention
device is shown. Like the embodiments shown in FIGS. 6A-8, the outer
sleeve wall 520 in the illustrated embodiment of FIG. 9 may also be
movable from its normally biased closed position (see right side sleeve
for normally biased closed position) to open the sleeve 510 beyond its
normal size to allow a user to easily slide a pouch P into the sleeve 510
(see left side sleeve for opened position). When the outer sleeve wall
520 is released, it biases back toward its normal position to gently
"squeeze" the pouch P. However, the outer wall 520 in the illustrated
embodiment of FIG. 9 is not hinged like the outer walls 220, 320, and 420
in the illustrated embodiments of FIG. 6A-8. In that regard, outer wall
520 in FIG. 9 acts like a leaf spring and is bendable from its normal
closed position to its opened position.

[0051] Now referring to FIG. 10A, a position limiter assembly 640 for a
leaf spring-type carrier 600 is shown. In the illustrated embodiment, a
carrier 600 is shown having two sleeves 610, one on the left side in a
normal open loading/unloading position, and one on the right side in a
closed processing position. Referring first to the open sleeve 610 on the
left side of the drawing, the second sleeve wall 620 is biased in the
open position and the position limiter assembly 640 extends unengaged
through a slot or hole 652 in the substantially vertical wall 650 of the
stationary surface 612. In the embodiments of FIG. 8, the substantially
vertical wall 450 of the stationary surface 412 extends for only a
portion of the distance between the top and bottom ends of the carrier
400. However, in the illustrated embodiment of FIG. 10A, the
substantially vertical wall 650 of the stationary surface 612 extends for
the entire distance between the top and bottom ends of the carrier 600.

[0052] Referring to FIGS. 10A and 10B, a stopping device 648 (shown as a
finger) may extend from the bottom surface of the position limiter
assembly 640 to prevent inadvertent opening and control the closing width
of the sleeve 610.

[0053] To close the open sleeve 610 on the left side of the drawing, the
position limiter assembly 640 is pushed to the right until the contact
surface 648 (shown as a pierced tab) disengages the lower inner surface
of the substantially vertical wall 650 of the stationary surface 612 (for
example, similar to the position shown on the rights side of the drawing,
but in minor image). Referring now to the closed sleeve 610 on the right
side of the drawing, the contact surface 648 engages the lower inner
surface of the substantially vertical wall 650 of the stationary surface
612, and the sleeve 610 is maintained in a closed position. To open the
closed sleeve 610 on the right side of the drawing, the position limiter
assembly 640 is pushed up to release the engagement of the contact
surface 648 and the lower inner surface of the substantially vertical
wall 650 of the stationary surface 612. The second sleeve wall 620 then
moves outwardly toward the substantially vertical wall 650 to rest in an
open position (for example, similar to the position shown on the left
side of the drawing, but in mirror image).

[0054] It should be appreciated that the carriers described herein are
designed with robust position limiting devices, such that the carriers
will remain in either of their designated open or closed positions as
they travel through handling and processing shocks. Moreover, it should
be appreciated that the carriers may be designed to have one or more
position limiting assemblies that are capable of stopping in more than
two (e.g., open and closed) positions. For example, the carriers may have
different open positions designed for different sized pouches. Although
the embodiments described herein generally include biasing members (such
as compression springs or leaf springs), it should be appreciated that
carriers without biasing members are also within the scope of the present
disclosure.

[0055] Referring now to FIGS. 11A-11D, views of an exemplary leaf
spring-type carrier 700 (similar to the embodiment in FIGS. 10A and 10B)
are shown. Although similar numbers are used for like parts in FIGS. 10A
and 10B, it should be noted that the carrier 600 shown in FIGS. 10A and
10B is a double sleeve carrier, and the carrier 700 shown in FIGS.
11A-11C is configured as a single sleeve carrier.

[0056] The sleeve 710 for receiving a pouch (not shown) is seen in FIGS.
11A and 11B. As can be seen in FIGS. 11A and 11B, the second sleeve
upright wall 720 is biased to a closed position, which can be opened by a
user grasping or otherwise using handle 726.

[0057] Referring to FIG. 11D, the second sleeve wall 720 (shown as a leaf
spring-type wall) is removable from the carrier 700. This type of
removable wall allows for modification to the carrier 700, for example,
to exchange parts (such as sleeve walls) to accommodate other types of
pouches having varying size or shape, or for maintenance or cleaning. In
the embodiment shown, the removable spring wall 720 includes a base 760
that is attachable to an end 762 or other portion of the carrier 700 by
coupling devices 764 (see FIG. 11A). In addition, the removable spring
wall 720 of the embodiment shown is designed to have a biasing action
into the closed position to hold and substantially evenly distribute the
contents of a pouch having a specific size and shape within the sleeve
710. It should be appreciated, however, that other biasing designs are
also within the scope of the present disclosure, for example, biasing to
the open position.

[0058] Various other embodiments of pouch retaining and release systems
will now be described. Referring to FIGS. 12A-13B, instead of a wall
being movable (as can be seen in the illustrated embodiments of FIGS.
6A-11D), fingers 830 and 930 extend from or through respective outer
walls 820 and 920 are used to "squeeze" the pouches P. Referring to FIGS.
12A and B, the fingers 830 extend from the wall and are bent at an angle
to apply compression force on the pouch P. Like the outer wall 520 shown
in the illustrated embodiment of FIG. 9, the fingers 830 in the
illustrated embodiment in FIGS. 12A and 12B are not hinged to the outer
wall 820. Rather, they act as leaf springs, being bendable from a normal
compressing position to an opened position. In that regard, the fingers
may be laser cut into the outer wall, then formed with a bend
configuration to provide suitable "squeeze" against the pouch P. The
fingers 830 may include a handle or another pulling device (not shown) to
pull them from the normal compressing position to the opened position.

[0059] In the illustrated embodiment of FIGS. 13A and 13B, the fingers 930
are attached to a hinge and torsion spring assembly 932 to rotate the
fingers 930 against the pouch P. Like the illustrated embodiment of FIGS.
12A and 12B, fingers 930 may include a handle or another pulling device
(not shown) to pull them from the normal compressing position to the
opened position.

[0060] Referring to FIGS. 14A and 14B, a body portion 1012 having movable
inner walls 1040 and stationary outer walls 1020 in the sleeves 1010 is
shown. In that regard, the inner walls 1040 are coupled by hinges 1042 to
the second end 1004 of the body portion 1012. A biasing linkage system
1044 can be used to move the inner side walls 1040 between a normal
compressing position (see FIG. 14A), and an opened position (see FIG.
14B).

[0061] The linkage system 1044 generally includes a cross bar 1046 biased
by a biasing member 1024 (such as a compression coil spring) into the
normal compressing position (see FIG. 14A), but movable to the opened
position (see FIG. 14B). The cross bar 1046 is pivotally coupled to links
1048 that are pivotably coupled to the inner walls 1040. As the cross bar
1046 is pushed down, the links 1048 pivot and push the inner walls 1040
inward. The inner walls 1040 pivot around hinges 1042 to enlarge the
openings 1008 of the sleeves 1010. A pushing device (not shown) may be
used to generate a force (shown as arrow F) on the cross bar 1046 to
activate the biasing linkage system 1044.

[0062] Referring now to FIGS. 15A and 15B, another embodiment of a pouch
carrier 1100 having a pouch loading and retention system is shown. In the
illustrated embodiment of FIGS. 15A and 15B, the substantially
cylindrical pouch carrier 1100 includes first and second portions 1150
and 1152 defining first and second pockets 1154 and 1156. The first and
second portions 1150 and 1152 are divided along a plane extending
longitudinally through the diameter of the first and second circular ends
1102 and 1104. The first and second portions 1150 and 1152 are hingedly
coupled to one another by a hinge 1160 and each includes a door 1162 and
1164 hingedly coupled so as to close each of the respective first and
second pockets 1154 and 1156. A carrier latch 1166 secures the carrier
1100 in the closed position.

[0063] During pouch loading, the pouch carrier 1100 is opened to receive
first and second pouches P. The pockets 1154 and 1156 are shaped to
constrain pouch motion, and in that regard, may be specifically designed
for certain kinds of pouches or generally designed to constrain the
motion of most pouches. After the pouches P have been loaded, the doors
1162 and 1164 are closed to snuggly fit over the pouches P and constrain
pouch motion. After the pouches have been loaded, at least one of the
first and second portions 1150 and 1152 is rotated around hinge 1160 to
latch together with latch 1166 and form a cylinder.

[0064] In addition to sleeve retention systems, as described above, sleeve
cross-sectional shape may also assist with pouch retention to minimize
movement of the pouch P within the sleeve and to more evenly distribute
the contents of the pouch P throughout the entire pouch P. Referring to
FIGS. 16A, 16B, and 16C, suitable cross-sectional shapes may include, but
are not limited to, trapezoidal (see FIG. 16A), with tapered ends (see
FIG. 16B) to accommodate the seal S along the outer peripheral edge of
the pouch P (see FIG. 2), and curved (see FIG. 16C). Referring to FIG.
17, a trapezoidal sleeve shape (for example, as shown in FIG. 16A) may be
combined with a hinged sleeve retention mechanism, such as that shown in
FIGS. 14A and 14B.

[0065] Now referring to FIGS. 18-20 various designs for rotary systems,
such as rotary sterilizers, are shown. It should be appreciated that
rotary systems may be designed to handle any number of carriers at any
given time. In FIG. 1, a test rotary sterilizer is shown, which is
capable of handling eight carriers at any given time. Suitable larger
diameter rotary sterilizers for use in production may be capable of
processing thousands of carriers at any given time.

[0066] It should be appreciated that the rotary systems may have an
agitating reel (see FIG. 19) or a non-agitating reel (see FIG. 20).
Referring to FIGS. 18 and 19, a rotary sterilizer 1200 including an
agitating reel 1204 will first be described. A rotary valve 1202 feeds
the reel 1204 of the rotary sterilizer 1200 with carriers 1206. The reel
1204 is surrounded by an outer shell 1208. The carriers 1206 are rotated
around the reel 1204 and are maintained in position along the reel 1204
by angles 1210 (see FIG. 19). In certain positions along the reel 1204,
the carriers 1206 may be supported by the outer shell 1208. In that
regard, when the carriers 1206 are on the upper portion of the reel 1204
they are supported by the reel 1204 itself, but when they are on the
bottom portion of the reel 1204, they are supported by the outer shell
1208 and pushed along the outer shell 1208 by the angle 1210 located
behind the carrier 1206 (see FIG. 19). When supported by the outer shell
1208, the carriers 1206 roll along the internal surface of the outer
shell 1208 and therefore the carrier contents are agitated by such
rolling action.

[0067] Referring now to FIG. 20, a portion of rotary system 1300 including
a non-agitating reel 1304 is shown. The rotary sterilizer of the
illustrated embodiment of FIG. 20 is substantially similar to the
illustrated embodiment of FIGS. 18 and 19, except for a difference
regarding the angles 1310. In that regard, the angles 1310 are designed
to carry and support the carriers 1306 when carriers 1306 are on the
bottom portion of the reel 1304. Because the carriers 1306 do not roll
along the internal surface of the outer shell 1308, the carrier contents
are not agitated by any rolling action.

[0068] With canned food, agitation may be desirable for certain food
types, for example, milk and other low-viscosity foods. With other
fragile foods, for example, lima beans, agitation may not be desired
because it may cause the beans to become broken or damaged. The advantage
of using a non-agitating rotary sterilizer with the many embodiments of
pouch carriers described herein is that agitation is minimized, which in
turn minimizes scuffing and wrinkling of the carried pouches P.
Therefore, in accordance with methods of the present disclosure for
processing pouches in rotary sterilizers, pouches may be placed in
cylindrical carriers and received in either agitating or non-agitating
rotary systems, such as rotary sterilizers.

[0069] Referring to FIGS. 21-23, intermittent and continuous unloading
systems 1340 and 1350, as well as a chute 1356 for receiving pouches that
are dropped downwardly from a carrier, are shown. Referring to FIGS. 21
and 22, the carriers 600 are supported by two laterally spaced apart
conveyors 1352 positioned far enough apart that the pocket openings of
the carriers 600 are positioned over the open width 1354 between the
conveyors 1352. In the illustrated embodiments of FIGS. 21-23, the
carriers do not rotate on the conveyors, but rather are supported by the
conveyors and/or by guide rails positioned beneath either of the first or
second ends of the carrier (see, e.g., FIG. 23 showing conveyors 1352
positioned beneath carrier 600). This support system maintains the
carriers in a non-rotating position, preferably with the openings to the
sleeves oriented downwardly.

[0070] In addition to conveyors 1352 for support, the systems 1340 and
1350 may also include an optional alignment feature. Using an alignment
feature, the carrier must be rotated or otherwise indexed to a correct
position for loading or unloading pouches. For example, using the
geometry of the carrier, if the central box containing the sleeves is
rectangular in shape, a carrier can thus be guided along conveyors such
that the long side of the box is parallel to travel. The orientation of
the pocket openings is thus known. In the illustrated embodiment of FIG.
23, guide rails 1358 run the length of the conveyors 1352, are parallel
to the conveyors 1352, and are configured for maintaining the carriers
600 on the conveyors 1352. In that regard, the carriers 600 may be top
heavy, and the guide rails 1358 will prevent them from toppling over.

[0071] At the appropriate time, the carriers 600 are acted upon to allow
the pouches P contained in the sleeves to drop downwardly from the
sleeves (largely by gravity). Referring to FIGS. 21 and 23, pulling
devices D (for example, as shown and described with reference to FIGS. 8
and 9) may be activated to move a carrier wall from a pouch retaining
position to a pouch release position. Referring to FIG. 22, a pulling bar
B may be positioned along the path of the conveyors 1352 to move a
carrier wall from a pouch retaining position to a pouch release position.
Such a pulling bar may be active, as described with reference to FIGS. 21
and 23, or it may be passive, for example, using a stationary bar with
sloped surfaces that "cam" the carrier wall to the pouch release position
as the carrier 600 moves along the conveyors 1352.

[0072] The pouches P will travel between the two supporting conveyors 1352
downwards onto appropriate chutes 1356 or take-away conveyors (see, e.g.,
FIG. 23). The action of unloading and dropping pouches could occur while
the carrier is either stopped (for example, at an "unload position"
showing in FIG. 21), or is moving along the support conveyors (for
example, see "unload zone" in FIG. 22). It should be appreciated that a
continuous unloading process may allow for faster system operating
conditions by reducing carrier stoppages.

[0073] Referring to FIGS. 21 and 22, mechanisms can be activated at the
"unload position" 1360 or "unload zone" 1370 to actuate a latch
mechanisms and open the sleeve of the container 600. To allow integration
with a full processing system, such as loading, unloading, and controls,
other features can be included in the carrier design, as described in
greater detail below. As one non-limiting example, the carriers may
include a "pouch present" feature. Such a feature may includes holes in
the walls of the carrier to allow photo eyes (for example) to shine
through the carrier to verify if the pocket does or does not contain a
pouch.

[0074] As another non-limiting example, the carriers may include "sleeves
up" feature for determining if the carrier is correctly oriented for
loading or unloading: sleeves upward, or downward, as required. For
example, the pocket openings can be sensed using eddy current proximity
sensors, magnetic sensors, or other appropriate sensors, and appropriate
action can be taken to remove incorrectly oriented carriers.

[0075] It should be appreciated that the carrier unloading processes of
FIGS. 21-23 may be adapted for use with any of the above-described
embodiments carriers. However, the carriers illustrated in FIGS. 21-23
generally include release mechanisms for unloading pouches (such as
position limiter assemblies shown in FIGS. 10A and 10B).

[0076] In accordance with these processes, carriers (as described above)
can be unloaded after processing by rotating or otherwise orienting the
carriers with the openings of the sleeves directed downwards, and
aligning the carrier so that the long side of the sleeve is, for example,
parallel to the path of travel along a conveyor. Likewise, carriers can
be loaded by orienting the carriers with the sleeves upwards, aligning
the carrier so that the long side of the sleeve is, for example, parallel
to the path of travel along a conveyor.

[0077] Now referring to FIGS. 24-27, other carrier embodiments are shown
for carrying other types of containers besides pouches. In that regard,
FIG. 24 is a bottle carrier 1400, FIG. 25 is a tub carrier 1500, and FIG.
26 is a fiberboard and plastic laminate container carrier 1600, all in
accordance with embodiments of the present disclosure. In accordance with
embodiments of the present disclosure, the carriers 1400, 1500, and 1600
of respective FIGS. 24-27 may include suitable retention systems (see
e.g., the retention system shown in FIG. 28).

[0078] Referring to FIG. 24, carrier 1400 includes a body portion 1412
having first and second ends, and an outer shell portion 1406. The body
portion 1412 includes a plurality of sleeves for receiving containers,
such as bottles. The shell and body portion 1406 and 1412 may be
perforated to allow for effective heat transfer. In the illustrated
embodiment, the shell portion 1406 is substantially cylindrical and the
first and second ends are substantially circular to allow the carrier
1400 to roll. Referring now to FIGS. 25 and 26, the respective carriers
1500 and 1600 are substantially similar to the carrier 1400 of FIG. 24,
but include different sized or shaped sleeves for receiving, for example,
tubs and laminate containers. Any of the carriers 1400, 1500, and 1600 of
respective FIGS. 24-26 may also be configured for receiving pouches.

[0079] As seen in FIG. 27, the body portions 1412, 1512, and 1612 of the
respective bottle, tub, and laminate container carriers 1400, 1500, and
1600 may each be interchangeable within a single outer shell portion
1406. Such interchangeability of parts allows for various types of
containers to be processed using the carrier system, as well as
replacement of worn parts without requiring replacement of the entire
carrier.

[0080] Referring now to FIGS. 28 and 29, alternate embodiments for carrier
assemblies are provided. The carriers 1700 and 1800 are substantially
cylindrical in shape, like the previously described embodiments; however,
they have differences regarding the positioning and orientation of the
sleeves 1710 and 1810 for carrying pouches P. For example, as shown in
FIG. 28, the sleeves 1710 are positioned to extend radially from the
center longitudinal axis of the container 1700. An optional
circular-shaped capping portion 1714 having a plurality of holes 1712 can
be fixed to the top surface 1716 of the container 1700. After pouches P
have been received in the sleeves 1710 through aligned holes 1712 in the
capping portion 1714, the capping portion 1714 may be turned relative to
the container 1700 and sleeves 1710 to misalign the holes 1712 in the
capping portion 1714 with the sleeves 1710. Such misalignment helps
maintain the pouches P in the sleeves 1710 during processing.

[0081] Referring now to FIG. 29, the sleeves 1810 are also positioned to
extend radially from the center longitudinal axis of the container 1800.
However, different from the embodiment shown in FIG. 28, the sleeves 1810
are accessed from the outer cylindrical surface 1816 of the container
1800. An optional cylindrical capping portion 1814 having a plurality of
holes 1812 can be fixed to the outer cylindrical surface 1816 of the
container 1800. After pouches P have been received in the sleeves 1810
through aligned holes 1812 in the capping portion 1814, the capping
portion 1714 may be turned relative to the container 1800 and sleeves
1810 to misalign the holes 1812 in the capping portion 1814 with the
sleeves 1810. Such misalignment helps maintain the pouches P in the
sleeves 1810 during processing.

[0082] Now referring to FIGS. 30-38, various carrier embodiments are shown
for carrying fragile or other irregularly-shaped containers, such as
thin-walled cans, shaped cans, and shaped plastic bottles. Thin-walled
cans are particularly fragile containers that can be damaged during
continuous processes. The advantages of such carriers are as follows: (1)
to prevent damage to the graphics on the cans; (2) to hold the can so
that it will not be released from the carrier, and also to restrict
movement to prevent rubbing; (3) to maximize the heat penetration through
the carrier so that it reaches the contents inside the can; and (4) to
handle irregular-shaped containers as though they are cylinders.

[0083] Referring to FIGS. 30-32, a carrier 1900 in accordance with one
embodiment of the present disclosure is shown. The carrier 1900 is
designed from molded plastic, such as polypropylene. The carrier 1900 may
be made from any suitable process, for example, injection molding
process. Holes along the exterior surface of the carrier 1900 may be used
to meeting molding parameters or reduce material usage, as well as
provide access for processing fluids.

[0084] The design generally includes a shaped area 1910 in the bottom of
the carrier 1900 for mating with the contoured bottom end of a typical
two-piece can, and plastic tabs 1920 at the upper end for mating with the
seam chimes or other geometry on the top end of a typical can. The points
of contact are therefore on the top and bottom ends of the can, to
prevent rubbing, denting, or other damage to the seam chimes and the
outer cylindrical wall of the can. This carrier 1900 can also be used
with a two-piece can, can loaded top-end first; with three-piece cans
having either end being captured by plastic tabs; or with plastic bottles
having tabs designed to capture an appropriate feature on the bottle.

[0085] Referring to FIGS. 33-35, a carrier 2000 in accordance with another
embodiment of the present disclosure is shown. The carrier 2000 includes
a main receiving portion 2002 and an insert portion 2004 for mating with
the main receiving portion 2002. The insert portion 2004 may be formed
from a compliant material, such as rubber or silicon. Like the carrier
1900 shown in FIGS. 30-32, the design includes a shaped area 2010 in the
bottom of the carrier 2000 for mating with the contoured bottom end of a
typical two-piece can. After the can has been received in the carrier
2000, the insert portion 2004 engages with the main receiving portion
2002 to hold the can in the carrier 2000.

[0086] Referring to FIGS. 36-38, a carrier 2100 in accordance with another
embodiment of the present disclosure is shown. The carrier 2100 includes
a main receiving portion 2102 and an insert portion 2104 for mating with
the main receiving portion 2102. The insert portion 2104 may be formed
from rubber or silicon or another suitable material having
compressibility and flexibility properties. The bottom or receiving
portion 2102 incorporates tabs 2106 that capture a feature on the can,
such as the seam chimes, to retain the can in the carrier 2100. An
appropriate feature on a container is a groove that the tabs 2106 can fit
into to restrict the container from falling out and to support the
fragile surfaces. For cans, this feature may be the necked-in diameter
adjacent the seam chimes For a plastic bottle, this feature may be the
tapered upper shoulder that approaches the bottle neck. The tabs 2106 are
preferably flexible enough to deflect when the container is inserted into
the carrier 2100, but then to flex back to into position when the
container is removed from the carrier 2100.

[0087] While illustrative embodiments have been illustrated and described,
it will be appreciated that various changes can be made therein without
departing from the spirit and scope of the disclosure.

Patent applications by Frederick James Wilson, Fresno, CA US

Patent applications by Kevin Andrew Carlson, Kerman, CA US

Patent applications by John Bean Technologies Corporation

Patent applications in class Using disinfecting or sterilizing substance

Patent applications in all subclasses Using disinfecting or sterilizing substance